Method of forming apparel having sensor system

Abstract

A method of forming an article of apparel having a sensor system includes extruding one or more polymeric materials onto the article of apparel to form one or a plurality of sensors. The polymeric material(s) may have a conductive particulate material dispersed therein. Conductive leads connecting the sensors to a port may also be formed of a polymeric material having a conductive particulate material dispersed therein. The conductive material may be dispersed in the sensor(s) at a first dispersion density and in the leads at a second dispersion density. Each of the sensors is configured to increase in resistance when deformed under pressure, which is detected by a module connected to the port. The second dispersion density is such that each of the leads has sufficient conductivity that the leads are configured to conduct an electronic signal between each sensor and the port in any state of deformation.

What is claimed is: 
     
       1. A method comprising:
 providing an article of apparel configured to be worn by a user; 
 connecting a port to the article of apparel, the port having an interface configured for communication with an electronic device; and 
 extruding a polymeric material onto the article of apparel to form a plurality of sensors configured to detect movement of the user wearing the article of apparel and a plurality of conductive leads electronically connecting the sensors to the port, comprising:
 extruding the polymeric material having a conductive particulate material dispersed therein at a first dispersion density to form the plurality of sensors, such that the sensors are configured to increase in resistance when deformed under pressure to detect movement of the user wearing the article of apparel; and 
 extruding the polymeric material having the conductive particulate material dispersed therein at a second dispersion density that is higher than the first dispersion density to form the plurality of conductive leads, such that the conductive leads are configured to conduct an electronic signal between the sensors and the port in any state of deformation. 
 
 
     
     
       2. The method of  claim 1 , wherein the interface is configured for communication with the electronic device by physical contact. 
     
     
       3. The method of  claim 1 , wherein the interface is configured for communication with the electronic device by wireless communication. 
     
     
       4. The method of  claim 1 , wherein the port further comprises a housing configured to receive the electronic device, such that the interface is configured for electrical contact with the electronic device within the housing. 
     
     
       5. The method of  claim 1 , wherein the plurality of sensors includes a first sensor, and the plurality of conductive leads includes a first conductive lead connecting the first sensor to the port, and wherein the first sensor and the first lead are integrally formed as a single extruded member having a sensor segment forming the first sensor and a conductor segment forming the first conductive lead. 
     
     
       6. The method of  claim 1 , further comprising co-extruding an insulative coating along with the polymeric material forming the sensors and conductive leads, such that the insulative coating covers the sensors and conductive leads. 
     
     
       7. The method of  claim 6 , wherein the insulative coating is formed of the polymeric material forming the sensors and the conductive leads. 
     
     
       8. The method of  claim 1 , further comprising;
 applying a bonding material to the article of apparel prior to extruding the polymeric material, such that the bonding material enhances a connection of the polymeric material to the article of apparel. 
 
     
     
       9. A method comprising:
 providing an article of apparel configured to be worn by a user; 
 connecting a port to the article of apparel, the port having an interface configured for communication with an electronic device; 
 extruding a first polymeric material onto the article of apparel to form a plurality of sensors configured to detect movement of the user wearing the article of apparel, the first polymeric material having a first conductive particulate material dispersed therein, wherein a conductivity imparted by the first conductive particulate material is such that the sensors are configured to increase in resistance when deformed under pressure to detect movement of the user wearing the article of apparel; and 
 extruding a second polymeric material onto the article of apparel to form a plurality of conductive leads electronically connecting the sensors to the port, the second polymeric material having a second conductive particulate material dispersed therein, wherein a conductivity imparted by the second conductive particulate material is such that the conductive leads are configured to conduct an electronic signal between the sensors and the port in any state of deformation. 
 
     
     
       10. The method of  claim 9 , wherein the interface is configured for communication with the electronic device by physical contact. 
     
     
       11. The method of  claim 9 , wherein the interface is configured for communication with the electronic device by wireless communication. 
     
     
       12. The method of  claim 9 , wherein the port further comprises a housing configured to receive the electronic device, such that the interface is configured for electrical contact with the electronic device within the housing. 
     
     
       13. The method of  claim 9 , wherein the plurality of sensors includes a first sensor, and the plurality of conductive leads includes a first conductive lead connecting the first sensor to the port, and wherein the first sensor and the first lead are integrally formed as a single extruded member having a sensor segment forming the first sensor and a conductor segment forming the first conductive lead. 
     
     
       14. The method of  claim 9 , wherein the first polymeric material and the second polymeric material are different materials. 
     
     
       15. The method of  claim 9 , wherein the first conductive particulate material and the second conductive particulate material are different materials. 
     
     
       16. The method of  claim 9 , wherein a difference between the conductivity imparted by the first conductive particulate material and the conductivity imparted by the first conductive particulate material results from differences in conductivity between the first and second conductive particulate materials. 
     
     
       17. The method of  claim 9 , wherein a difference between the conductivity imparted by the first conductive particulate material and the conductivity imparted by the first conductive particulate material results from differences in dispersion density between the first and second conductive particulate materials. 
     
     
       18. The method of  claim 9 , further comprising co-extruding a first insulative coating along with the first polymeric material forming the sensors and co-extruding a second insulative coating along with the second polymeric material forming the conductive leads, such that the first insulative coating covers the sensors and the second insulative coating covers the conductive leads. 
     
     
       19. A method comprising:
 providing an article of apparel configured to be worn by a user, the article of apparel having a port having an interface configured for communication with an electronic device; 
 extruding a first polymeric material segment onto the article of apparel to form a first sensor configured to detect movement of the user wearing the article of apparel, the first polymeric material segment having a first conductivity such that the first polymeric material segment is configured to increase in resistance when deformed under pressure to detect movement of the user wearing the article of apparel; 
 extruding a second polymeric material segment onto the article of apparel to form a first conductive lead electronically connecting the first sensor to the port, the second polymeric material segment having a second conductivity such that the first conductive lead is configured to conduct electronic signals between the first sensor and the port in any state of deformation; and 
 extruding a third polymeric material segment onto the article of apparel to form a second conductive lead electronically connecting the first sensor to the port, the third polymeric material segment having a third conductivity such that the second conductive lead is configured to conduct electronic signals between the first sensor and the port in any state of deformation, 
 wherein the first polymeric material segment, the second polymeric material segment, and the third polymeric material segment are integrally formed as a single extruded member. 
 
     
     
       20. The method of  claim 19 , wherein the first polymeric material segment, the second polymeric material segment, and the third polymeric material segment formed of a same polymeric material. 
     
     
       21. The method of  claim 19 , wherein the first polymeric material segment, the second polymeric material segment, and the third polymeric material segment have one or more conductive particulate materials dispersed therein. 
     
     
       22. The method of  claim 19 , further comprising:
 co-extruding a first insulative coating along with the first polymeric material segment, such that the first insulative coating covers the first sensor; 
 co-extruding a second insulative coating along with the second polymeric material segment, such that the second insulative coating covers the first conductive lead; and 
 co-extruding a third insulative coating along with the third polymeric material segment, such that the third insulative coating covers the second conductive lead.